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A/T Clutch Clearance Inspection

Special Tools Required

Clutch compressor attachment
 07ZAE-PRP0100
  1. Install the clutch piston in the clutch drum. Do not install the O-rings on the clutch piston during inspection.

  1. Install the wave spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.

  1. Install the wave spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.

  1. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.

  1. Install the wave spring (A) in the 3rd clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.

  1. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.

  1. Install the snap ring with a screwdriver to secure the clutch end-plate.

  1. Set a dial indicator (A) on the clutch end-plate (B).
  1. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).

  1. Release the clutch end-plate to lower it, then put the clutch compressor attachment on the end-plate (A).
  1. For the 1st, 3rd, and 5th clutches:
    Press the clutch compressor attachment down with 150−160 N (15−16 kgf, 33−35 lbf) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
  1. For 2nd and 4th clutches:
    Press the clutch compressor attachment down with 39 N (4 kgf, 9 lbf) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
    Clearance between Clutch End-Plate and Top Disc
    Service Limit
    1st clutch:
    1.62−1.82 mm (0.064−0.072 in.)
    2nd clutch:
    0.5−0.7 mm (0.020−0.028 in.)
    3rd clutch:
    0.73−0.93 mm (0.029−0.037 in.)
    4th clutch:
    0.7−0.9 mm (0.028−0.035 in.)
    5th clutch:
    0.73−0.93 mm (0.029−0.037 in.)


  1. If the clearance of the 1st, 3rd, or 5th clutch is out of the service limit, select a new clutch end-plate from the following table.

1ST CLUTCH END-PLATES

Mark
Part Number
Thickness
1
22551-RPC-003
2.1 mm (0.083 in.)
2
22552-RPC-003
2.2 mm (0.087 in.)
3
22553-RPC-003
2.3 mm (0.091 in.)
4
22554-RPC-003
2.4 mm (0.094 in.)
5
22555-RPC-003
2.5 mm (0.098 in.)
6
22556-RPC-003
2.6 mm (0.102 in.)
7
22557-RPC-003
2.7 mm (0.106 in.)
8
22558-RPC-003
2.8 mm (0.110 in.)
9
22559-RPC-003
2.9 mm (0.114 in.)


3RD and 5TH CLUTCH END-PLATES

Mark
Part Number
Thickness
1
22561-RPC-003
2.1 mm (0.083 in.)
2
22562-RPC-003
2.2 mm (0.087 in.)
3
22563-RPC-003
2.3 mm (0.091 in.)
4
22564-RPC-003
2.4 mm (0.094 in.)
5
22565-RPC-003
2.5 mm (0.098 in.)
6
22566-RPC-003
2.6 mm (0.102 in.)
7
22567-RPC-003
2.7 mm (0.106 in.)
8
22568-RPC-003
2.8 mm (0.110 in.)
9
22569-RPC-003
2.9 mm (0.114 in.)


  1. If the clearance of the 2nd or 4th clutch is out of the service limit, remove the clutch end-plate and check the clutch end-plate mark. Select a new clutch end-plate from the following tables by the mark on the old clutch end-plate. Use the AC-AL Plates table when the old clutch end-plate is marked with between AC and AL. Use the AM-AV Plates table when the old clutch end-plate is marked with between AM and AV.

2ND and 4TH CLUTCH END-PLATES AC-AL Plates

Mark
Part Number
Thickness
AC
22551-RPC-004
2.1 mm (0.083 in.)
AD
22552-RPC-004
2.2 mm (0.087 in.)
AE
22553-RPC-004
2.3 mm (0.091 in.)
AF
22554-RPC-004
2.4 mm (0.094 in.)
AG
22555-RPC-004
2.5 mm (0.098 in.)
AH
22556-RPC-004
2.6 mm (0.102 in.)
AJ
22557-RPC-004
2.7 mm (0.106 in.)
AK
22558-RPC-004
2.8 mm (0.110 in.)
AL
22559-RPC-004
2.9 mm (0.114 in.)


AM-AV Plates

Mark
Part Number
Thickness
AM
22561-RPC-004
2.1 mm (0.083 in.)
AN
22562-RPC-004
2.2 mm (0.087 in.)
AP
22563-RPC-004
2.3 mm (0.091 in.)
AQ
22564-RPC-004
2.4 mm (0.094 in.)
AR
22565-RPC-004
2.5 mm (0.098 in.)
AS
22566-RPC-004
2.6 mm (0.102 in.)
AT
22567-RPC-004
2.7 mm (0.106 in.)
AU
22568-RPC-004
2.8 mm (0.110 in.)
AV
22569-RPC-004
2.9 mm (0.114 in.)

  1. Install the new clutch end-plate and recheck the clearance. If the thickest clutch end-plate is installed but the clearance is still over the service limit, replace the clutch discs and plates.